Side lap vapor vent



Jan. l, 1967 J, 5 HlCKMAN Re. 26,141

SDE LAP VAPOR VENT 2 Sheets-Sheet l Original Filed Aug. l5, 1960 Jan.10, 1967 1 5 HICKMAN Re. 26,141

SIDE LAP VAPOR VENT 2 Sheets-Sheet Original Filed Aug. l5 1960 gy ff W5United States Patent O Re. 26,141 Reissuecl Jan. 10, 1967 ice 26,141SIDE LAP VAPOR VENT John S. Hickman, Shorewood. Wis., assigner to InlandSteel Products Company, Milwaukee, Wis., a corporation of DelawareOriginal No. 3,208,189. dated Sept. 28, 1965. Ser. No.

49,466, Aug. 15, 1960. Application for reissue Nov.

S, 1965, Ser. No. 507,083

13 Claims. (Cl. 52-534) Matter enclosed in heavy brackets [f] appears inthe original patent but forms no part of this reissue specification;matter printed in italics indicates the additions made by reissue.

This invention relates to metal roof-deck panels which are formed ascorrugated sections having sloped-web ribshaped cross-sections.

Roof deck panels which generally compris@ a plurality of corrugarinnsthat are parallel to a pair f opposite .side edges of the panel, areused as a support for roof or floor construction proper which consistsusually of mixtures of concrete containing aggregate fill over which indesired arrangement may be layers of asphalt ll, tar and gravel, or anyot them. To preserve the structure and to expedite construction, thepresent invention nrovides easy draining features. This is donc byproviding a plurality of raised or embossed elements formed into atleast the web or the trough-like side-lap portions nearest the paneledge.

These embossings are arranged to extend outwardly in such fashion thatwhen two deck panels are arranged in cooperating relationship to eachother with their end sections overlapped, a spaced-apart relationship isestablished between them so that any mixture remaining in the insulatingconcrete slab after pouring upon the roofdeck panels and subsequent tothe time a built-up formation has been applied thereover is adequatelyvented in the overlapped panel regions.

The built-in embossings herein to be described are raised or pressedoutwardly from the surface of the sidelap web portions so that completenesting together of overlapping trough-like web portions of adjacentlypositioned roof-deck sections cannot occur. Consequently, escape of`moisture from any coverings thereover is insured in the free spacebetween the panel sections.

In roofing construction employing lightweight concrete slabs over thedeck sections for insulation purposes, venting of entrapped moisture inthe slab has been a problem that has faced the trade for some time.Lightweight concrete insulating roof construction consists generally ofsteel joists with galvanized roof-deck panels welded to the joists. Alightweight insulating concrete slab with a tar and gravel covering isusually applied over the panels to form the built-up roof. Perlite andvermiculite types of insulating concrete are the most popular andfrequently used for such coverings. It is particularly the use of theselightweight fills of concrete mix that creates the need for a side-lapvent.

These lightweight aggregate fills are generally a well saturated mix tofacilitate easier pouring of the slabs and the volume of water in theinitial mix is considerably in excess of that required for normalconcrete hydration. Venting of this free and excess water following theapplication of the tar and gravel built-up roofing over the insulatingslab is important since it has been found uneconomical to delay thefinal construction and application of the covering elements until afterthe aggregate has completely cured and dried out.

In the past, various types of vent clips were used on the overlappedsloped trough-like web portions to prevent complete nesting together ofoverlapped panels which otherwise would restrict and close off themoisture escape route and leave large quantities of moisture entrappedin the concrete slab. Entrapped moisture held under the built-up rootingoften led to roof failure because of the tendency of blisters to developin the built-up roofing due to the created vapor pressure developedwithin the roof as heat from the sun caused the roof temperature to riseand thereby produce vaporization of enttapped water. Since theatmospheric pressure above the roof was lower than the vapor pressurewithin the concrete slab, the only escape of the vapor was by way of aproduced blister which came about with the roof failure.

The present invention makes possible the complete elimination of ventclips by a positive venting system provided by the structural featuresherein to be dcscribed. As the roof deck panels of the present inventionare constructed, the sloping trough-like web sections of the panelside-lap portions have embossings extending outwardly therefrom. Whilesuch eiubossings may assume various configurations` they will herein beillustrated and described in the forms of ribs or dimples. In the caseof a rib construction the embossing extends in a direction substantiallytransverse of or normal to the longitudinal axis of the side-lapportions. They are located at selected positions and distances along thelongitudinal axis of the web and, with assembly of adjoining panelsections, prevent the nesting together of the adjacent sloping sides andbottoms of the trough-like web portions. Similarly. in thc case ofdimples, the sloped roof deck panels are spaced and also thereby insurea built-in venting system from which moisture contained within theconcrete covering the slab can escape into the interior of the buildingbelow to eliminate the hazard of structural failure.

The invention will now be described in two of its forms in conjunctionwith the accompanying drawings in which:

FIG. l is an isometric view of portions of two adioining corrugatedroof-deck panels, showing the sloping wall trough-like side-lap portionsin overlapped relationship having at their edge regions embossings inthe form of transverse built-in ribs for maintaining the side-lapportions in a spaced-apart relationship relative to adjoining panels tocreate a vent therebetween;

FIG. 2 is a plan view of two overlapping trough-like, side-lap portionsshowing the transverse built-in ribs on different center-to-centerdimensions along the longitudinal axis ofthe side-lap portions toprevent any possible lapping of the ribs which would preclude properventing:

FIG. 3 is a sectional view taken through line 3 3 of FIG. 2, to showmore clearly the spaced-apart relationship between the overlappingtrough-like side-lap portions;

FIG. 4 is a sectional view taken through line 4-4 of FIG. 2 showing anend view through one of the transverse ribs having the spaced-apartrelationship of the overlapped trough-like side-lap portions creating avent system therebetween;

FIG. 5 is an isometric view of a section of a built-up roof showinganother embodiment of the invention, with the trough-like side-lapportions being embossed with outwardly extending dimpled, rather thanribbed, regions to locate the overlapping side-lap portions in aspaced-apart relationship to provide a vent therebetween;

FIG. 6 is a plan view of two overlapping trough-like side-lap portionsshowing the dimples on different centerto-center dimensions along thelongitudinal axis of the side-lap portion to prevent any possiblelapping of the dimples which would preclude proper venting;

FIG. 7 is a sectional View taken through line 7 7 of FIG. 6 showing thedimples holding the overlapping trough-like side-lap portions in aspaced-apart relation- 3 ship, thereby creating a venting systemtherebetween; and

FIG. 8 is a sectional view taken through line 8*8 of FIG. 6 showing anend view through the dimples to provide the spaced-apart relationship ofthe overlapped trough-like sidelap portions creating a vent systembetween the spaced-apart side-lap portions.

Now, referring to the drawings and specifically to FIG. 1, thereof, forthe purpose of indicating the iinal use of the invention, two sectionsof roof-deck panels 10 and l1, each having an upper edge 40 dening aterminal side wall edge are shown in the form of corrugated sectionswith their respective oppositely spaced inner 30 and outer 32 side wallsbeing connected by a bottom wall 31 forming the trough-shaped portions12 and 13 shown in an overlapping relationship. The trough-shapedportions of the panels are connected together by top walls 42.Embossings or embossing means are formed in these members as built-inribs 14 and 15 which extend substantially transverse to the longitudinalaxis of panel webs as to the panel edge. Each of the transverse ribs 14and which extend outwardly from the roof section, as indicated, ispreferably formed on different center-tocenter spacings resulting in arib staggering suiicient to prevent a cut-off of the venting systemtherebetween no matter how far out of tolerance the ribs may be or atwhat angle the edge ribs nest.

An enlargement of the two overlapping web portions 12 and 13 is shown inFIG. 2 which emphasizes the staggered positions of the ribs 14 of theweb portion 12 and the ribs 15 of the web portion 13. A similarrelationship is also shown in FIGS. 3 and 4. Illustratively, in apreferred construction, the rib depth may be a relatively minordistance, say one-sixteenth inch, since the main feature is to precludethe web sections from contacting each other over their entire area.Great tolerance is permissible in the rib width and, illustratively, andwithout limitation the rib may be of chosen width, such as 1A" to l orwider. The ribs may be embossed or formed in various ways into the metalof the deck. Where the ribs are of uniform width stationary or flyingdies are frequently used to form the structure, depending upon themanufacturing process. If the rib formation is to be tapered, each ofwhich forms is herein clearly contemplated, so as to be wider at its topor outer end than at the bottom, the formation is readily provided bycycloid shaped meshed rolls.

Another embodiment of the present invention which employs the same broadprinciple and also insures a positive venting system is shown by FIGS.5, 6, 7, and 8 of the drawings. In these figures the built-in ribs arereplaced by dimples extending outwardly from the troughlike webportions. The dimples are selectively located to maintain the webportions of adjoining roof-deck panels in assembly in a spaced-apartrelationship to provide a venting system therebetween.

A portion of a built-up roof of the type in which the present inventionis particularly suitable for use is shown in FIG. 5 with sections ofadjoining roofdeck panels 16 and 17 shown with their respectivetrough-like web portions 18 and 19 in overlapping relationship. The webportion 19 has dimples 21 which are raised from the web portion to abutthe underlying web portion 18 of the roof-deck panel 16 and therebymaintain overlapping trough-like web portions 13 and 19 in aspaced-apart relationship and provide a venting system therebetween.

Each construction is such that a covering of lightweight concrete 22containing lightweight aggregate fill, such as Perlite, vermiculite, orthe like, is poured upon the roof-deck panels 16 and 17. Over thislightweight concrete slab there is usually a layer of asphalt 23 uponwhich the built-up roofing consisting of building felt 24, tar 25, andgravel 26 is applied in as many layers or combinations as may be desiredor warranted by the roofing required.

An enlargement of the two overlapping trough-like web portions 18 and 19similar to that shown in FIG. 3 sets forth the selective placement ofthe dimples 21 of web portion 19 with respect to the dimples 27 of webportion 18, as shown in broken lines underlying the web portion 19. Thedimples 21 of web portion 19 are arranged so as to abut the surface ofweb portion 18 and thereby maintain webs of the adjoining roof-deckpanels 16 and 17 in a spaced-apart relationship and provide a ventingsystem therebetween.

The venting system between the trough-like web portions 18 and 19 isalso shown in FIG. 7, which is a sectional view taken through the lines7 7 of FIG. 6 to show the dimples maintaining the Webs in theirspaced-apart relationship. The spaced-apart relationship of the twoside-lap portions 18 and 19 is also shown in FIG. 8 which shows thedimples 21 of web portion 19 abutting the surface of web portion 18 andthe raised dimples of portion 18 abutting the surface of portion 19 toretain the two webs in the required spaced-apart relationship forventing.

Thus, as clearly shown, for example, in FIGS. 7 and 8, Ille outer sidewall defining the outermost corrugalt'on of the panel is deformedalternately along the extent of the side wall inwardly and outwardly.

The portion along the inner wall of the trough-shaped portions locatedalong the terminal edges of the panel is not deformed as seen in FIGS.6-8 such that i! is substantially constant along a Straight path forsubstantially :he length of the respective trough-shaped portion.

As an illustration of the construction procedure, since the most populartypes of aggregate used in light-weight insulating concrete are Perliteand vermiculite and since to saturate these aggregates, a larger volumeof water than that normally required for concrete hydration is used tofacilitate easy pouring of the roof, the amount of water contained insuch a slab after pouring is large. In the construction for a 2.1/2"fill over the roof-deck panels using a 1 to 6 mix (which means that 1bag of cement, containing approximately 1 cubic foot of cement or 94pounds is to be mixed with 6 cubic feet of lightweight aggregate such asPerlite or vermiculite) the water formula and drying conditionspreferably should be such that the water content in the concrete wouldbe as follows:

PERLITE MIX Days after Water content, pouring: qts./sq. ft.

VERMICULITE MIX Days after Water content, pouring: qts./sq. ft

The built-up rooting is usually applied over the lightweight insulatingconcrete slab after about seven days, whereupon there is always animpervious waterproof membrane over the concrete. This inventionprovides ways and means by which any entrapped moisture can readily bevented when the rib sections maintain a desired spacing betweenoverlapped sections of the roof.

The roof-deck panel is usually made from galvanized sheet steel and maybe considered as carrying the roof load. The ribs herein explained anddiscussed have been shown as extending outwardly, which is the preferredconstruction with a rather high tensile, low percent elongation deckmaterial. For some conditions, however, it is possible to have theventing ribs extend in the opposite or inwardly direction. This isparticularly true in cases where the galvanized steel sheet is ofrelatively low tensile higher percent elongation, making it easy tocarry for- Ward the embossing process in either direction, as desired.Therefore, it is to be understood that the invention, while shown in itspreferred form, is also capable of being carried by reversing theprocedure described.

Havingr now describe-d the invention, what is claimed is:

l. A roof deck over which moisture bearing construction material can bepoured, said roof deck comprising:

a plurality of overlapped panels;

each of said panels having a lapped edge;

each of said panels having a trough-shaped portion extending along saidlapped edge;

each of said trough-shaped portions having a bottom wall and oppositeinner and outer side Walls connected by said bottom wall;

the outer side wall of each of said trough-shaped portions having anupper edge dening a terminal side wall edge on each of said panels,

said trough-shaped portion which extends along a lapped edge of one ofsaid panels overlapping and nesting with at least part of saidtrough-shaped portion which extends along a lapped edge of an adjacentpanel, so that the outer side wall of one trough-shaped portion on oneof the overlapped panels is adjacent the inner side wall of saidadjacent nested trough-shaped portion ot the other of the overlappedpanels to form a first set of nested adjacent side Walls, and the innerside wall of said one trough-shaped portion is adjacent the outer sidewall of said adjacent nested troughshaped portion to form a second setof nested side walls;

spacing means projecting away from one of said side walls of said rstset of nested side walls and abutting the other side wall of said rstset: and spacing means projecting away from one of said side walls ofsaid second set of nested side walls and abutting the other side wall ofsaid second set; said spacing means positively spacing the side andbottom Walls and said upper edge of each of said nested trough-shapedportions from any substantial Contact with the side and bottom walls andupper edge of the other of said nested trough-shaped portions; saidspacing means being disposed at spaced intervals along the length ofsaid trough-shaped portions, thereby dening a transversemoisture-venting passageway between the nested trough-shaped portions.

2. A roof deck in accordance with claim 1 and including spacing meansprojecting away from all the walls of said overlapped and nestedtrough-shaped portions.

3. A rectangular metal slzeet having a plurality of spaced longitudinaltrough-shaped portions parallel to a pair of opposite side edges;

the outermost trough-shaped portion along each of said pair of sideedges dehning the terminal side portion of the sheet;

each outermost trough-shaped portion having an upwurdly and outwardlyinclined substantially planar outer side wall terminating as one of saidside edges;

a substantially planar bottom wall extending transversely of said sideedge as a continuation of the lower portion of the outer side wall todefine the base of said respective outermost trough-shaped portion:

an upwardly and inwardly inclined inner side wall extending as acontinuation of said respective bottom wall and to a position at leastabove a plane containing said side edges; a plurality of top wallsextending transversely of said side edges connecting said spacedtrough-shaped portions;

both of said upwardly and outwardly inclined outer side walls of saidoutermost trough-shaped portions having venting and spacing meansprojecting away there from, said venting and spacing means beingdisposed at spaced intervals along the length of said outer side walls,the remainder of said outer side walls being substantially smooth, und

said top walls and remaining trough-shaped portions being substantiallysmooth and free of said venting and spacing means.

4. A rectangular metal sheet in accordance with claim 3 wherein saidventing and spacing means project away from said bottom and inner sidewalls of said outermost trough-shaped portions, said venting and spacingmeans being disposed at spaced intervals along the length of said bottomand inner side walls, the remainder of said outer bottom and inner sidewalls being substantially smooth` 5. A rectangular metal sheet inaccordance with claim 3 wherein said venting and spacing means nre ribs.

6. A rectangular metal sheet in accordance with claim 3 wherein saidventing and spacing means are dimples.

7. A rectangular metnlsheet having longitudinal troughshaped portionsparallel to a pair of opposite side edges, the outermost trough-shapedportion along euch of stlid pair of side edges defining the terminalside portion of the sheet.'

each outermost trough-shaped portion having an upwardly and outwardlyinclined outer side wall terminating as one of said side edges;

a bottom wall extending transversely of said side edge as a continuationof the lower portion of the outer side wall to define the base of saidrespective outermost trough-shaped portion;

an upwardly and inwardly inclined inner side wall extending as acontinuation of said respective bottom wall;

a plurality of top walls extending transversely of said side edgesconnecting said trough-shaped portions;

each of said upwardly und outwardly inclined outer side walls havingventing and spacing means projecting away therefrom;

said venting and spacing means being located at spaced intervals alongthe extent of said outer side wall, the remainder of said outer sidewall being substantially smooth; and

the inner side wall of each of said outermost troughshaped portionsbeing substantially smooth und free of said venting and spacing meansfor substantially the length of the respective outermost trough-shapedportions.

8. A rectangular metal sheet in accordance with claim 7 wherein saidventing and spacing means project transversely inwardly and outwardlyalong the extent of said outer side wall.

9. A rectangular metal sheet in accordance with claim 7 wherein saidventing and spacing means are dimples.

10. A concrete form comprising a plurality of adjacent metal sheets;

each sheet having longitudinal trough-shaped portions parallel to u pnirof opposite side edges;

the outermost trough-shaped portion along each of said pair of sideedges defining a terminal side portion of the sheet;

at least one of said outermost trough-shaped portions lapping andnesting with at least a portion of an outermost trough-shaped portion ofon adjacent sheet;

each outermost trough-shaped portion having un upwardly and outwardlyinclined outer side wall terminating as one of said side edges;

o bottom wall extending tranversely of said side edge us a continuationof the lower portion of the outer side wall to dehne the base of saidrespective outermost trough-shaped portion and un upwardly and inwardlyinclined inner side wall extending as a continuation of said respectivebottom wall and to a position at least above a plane containing saidside edges;

a plurality of top walls extending transversely of said side edgesconnecting said trough-shaped portions;

each 0j said upwardly and outwardly inclined outer side walls havingventing and spacing means projecting away therefrom;

said venting and spacing means being located at spaced intervals alongthe extent of said outer side wall.'

the inner side wall of each of said outermost troughshaped portionsbeing substantially smooth and free of said venting and spacing meansfor substantially the length of the respective outermost trough-shapedportions;

whereby said spacing means on said outer side wall on tlze rst of saidnested trough-shaped portions abats said inner side wall of saidremaining nested troughshaped portion and said spacing means on saidouter side wall of said remaining trough-shaped portion abats the innerside wall of said first trough-shaped portion thereby defining atransverse moisture-venting passageway between the nested and lappedoutermost trough-shaped portions of adjacent sheets.

Il. A form in accordance with claim 10 wherein said spacing means aredimples.

12. A form in accordance with claim 10 wherein said spacing meansproject from all of the walls of said lapped and nested trough-shapedportions.

13. A form in accordance with claim 12 wherein said spacing means areribs.

References Cited by the Examiner The following references, cited by theExaminer, are of record in the patented le of this patent or theoriginal 5 patent.

UNITED STATES PATENTS FOREIGN PATENTS Germany. Great Britain.

20 FRANK L. ABBOTT, Primary Examiner.

M. O. WARNECKE, Assistant Examiner.

